Finite-element investigation of wear in hot forging

In this study, the wear profile on the die surface during the hot forging operation for an axisymmetric cross-section is examined. In the field of metal forming, reliable estimations of die wear and its distribution on the die surfaces can greatly influence the life of the forging dies. The amount of wear is calculated for two wear models by implementing a rigid thermo-viscoplastic finite element analysis into the metal forming process. The first model consists of the classical model which proposes that the amount of the wear is proportional to the die pressure and sliding length. Whereas, the second model assumes that the wear is proportional to the energy dissipated on the tool/workpiece contact interface. Finally, the influence of the friction on the amount of die wear and the material flow is discussed. From this study, it is found that these models are in agreement with each other. They are also consistent with the prediction of the location of heavily worn areas on the die surface. It was also concluded that the increase of friction coefficient does not enhance the die wear in general.

Finite-element investigation of wear in hot forging Keywords:

Wear , friction , hot forging , rigid thermo-viscoplastic finite element